US5064467A - Method and apparatus for the direct reduction of iron - Google Patents
Method and apparatus for the direct reduction of iron Download PDFInfo
- Publication number
- US5064467A US5064467A US07/455,232 US45523289A US5064467A US 5064467 A US5064467 A US 5064467A US 45523289 A US45523289 A US 45523289A US 5064467 A US5064467 A US 5064467A
- Authority
- US
- United States
- Prior art keywords
- gas
- iron
- reforming
- reduction
- range
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B13/00—Making spongy iron or liquid steel, by direct processes
- C21B13/04—Making spongy iron or liquid steel, by direct processes in retorts
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B13/00—Making spongy iron or liquid steel, by direct processes
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/10—Reduction of greenhouse gas [GHG] emissions
- Y02P10/122—Reduction of greenhouse gas [GHG] emissions by capturing or storing CO2
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/10—Reduction of greenhouse gas [GHG] emissions
- Y02P10/134—Reduction of greenhouse gas [GHG] emissions by avoiding CO2, e.g. using hydrogen
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/10—Reduction of greenhouse gas [GHG] emissions
- Y02P10/143—Reduction of greenhouse gas [GHG] emissions of methane [CH4]
Definitions
- the present invention is drawn to a process for the direct reduction of metal oxides containing iron to a metallized iron product.
- Known processes for the direct reduction of iron oxide to metallic iron utilize a reformed gas as the reducing agent. Natural gas is used as a source for generating the reformed gas.
- the reformed gas for use in the direct reduction process is generated in a unit called a reformer by contacting the natural gas with an oxygen containing material in the presence of a catalyst, usually a nickel catalyst, which activates the reformation reaction of the natural gas so as to yield a reformed gas which is rich in H 2 and CO.
- the reformed gas which is collected from the reformer is thereafter fed to a reduction reactor containing the iron oxide material wherein the direct reduction reaction is carried out.
- direct reduction processes heretofore known require two distinct reaction zones for carrying out the actual direct reduction process. In these conventional processes it is required that the reformed gas product in the first zone be treated prior to entering the reduction zone in order to remove CO 2 and/or water vapor.
- the present invention is drawn to a process for the direct reduction of metal oxides containing iron to a metallized iron product and an apparatus for the direct reduction of the metal oxides with the reformed gas.
- the process for the direct reduction of metal oxides containing iron to a metallized iron product in accordance with the present invention comprises providing a reduction reactor having a single reaction zone and partially metallized iron oxide material and direct reduced iron (DRI) in the reaction zone, forming a reformed reduction gas rich in H 2 and CO having an oxidation degree in the range of from about 0.05 to about 0.08 in the reaction zone, and contacting the iron containing metal oxide material in the reaction zone with the reformed reducing gas to effect reduction of iron oxide to iron.
- DRI direct reduced iron
- the reformed gas is produced by mixing top gas recycled from the reactor with natural gas, preheating the gas mixture to a temperature in the range of from about 650° C. to about 850° C., mixing air, preferably enriched with oxygen, preheated to a temperature in the range from about 650° C. to about 850° C. with the preheated top gas and natural gas mixture in a mixing chamber and introducing said gases having an oxidation degree of from about 0.30 to about 0.35 into the reaction zone. Exposure of this gas mixture to the hot DRI metallized iron in the reaction zone causes a highly endothermic reforming reaction.
- the resulting reformed reduction gas has a composition by volume consisting essentially of from about 45% to about 48% hydrogen, from about 32% to about 34% carbon monoxide, from about 2% to about 4% carbon dioxide, from about 1% to about 3% methane, from about 14% to about 16% nitrogen and from about 1% to about 3% water vapor having an oxidation degree in the range of from about 0.05 to about 0.08 in the reduction zone.
- the process of the present invention allows for a single reaction zone of a direct reduction reactor to be employed for the simultaneous production of the reformed gas for use in the reduction process and the actual direct reduction of the iron containing oxide material. It has been found that this simultaneous reforming-reduction approach greatly improves the overall efficiency of the reduction process. It also permits the reduction process to be carried out at much reduced levels of energy consumption.
- the average total energy consumption of the process is calculated to be about 9.4 GJ per ton of product of which about 2.3% is supplied as electrical energy.
- the FIGURE is a schematic illustration of an apparatus for performing the process of the present invention.
- the process for the direct reduction of iron-containing metal oxides to a metallized iron product of the present invention may be carried out using the apparatus schematically illustrated in the FIGURE.
- the apparatus comprises a reduction reactor 10 having a combined reforming--reduction reaction zone 12, an iron oxide feed preheat and prereduction zone 14, an inlet 16 for introducing an iron-containing metal oxide feed into the reactor, and an outlet 18 for withdrawing direct reduced metallized iron.
- the reactor also has an outlet 20 for permitting the removal of top gases.
- the iron-containing metal oxides introduced into the reactor may be in pellet form. Typically, they contain from about 63% to about 68% iron by weight.
- the direct reduced iron withdrawn from the reactor typically contains from about 85% to about 90% iron by weight.
- the top gas which is withdrawn has a composition by volume consisting essentially of from about 28% to 36% hydrogen, from about 17% to about 21% carbon monoxide, from about 13% to about 17% carbon dioxide, from about 2% to about 7% methane, from about 16% to about 18% nitrogen and from about 12% to about 17% water vapor.
- Its temperature is typically in the range of from about 300° to about 350° C. It also typically has a degree of oxidation ⁇ o the range of from about 0.33 to 0.35 and reducing power ⁇ R in the range of 1.6 to 1.7.
- ⁇ o the degree of oxidation ⁇ o the range of from about 0.33 to 0.35 and reducing power ⁇ R in the range of 1.6 to 1.7.
- the top gases withdrawn from the reactor 10 are passed to a unit 22 via conduit 23 for cooling the gases to a temperature in the range of about 40° C. to about 60° C. and for removing water.
- the amount of water remaining in the gases after they pass through unit 22 is from about 1% to about 3% by volume.
- the unit 22 may comprise any suitable water separator know in the art.
- the top gas is split. A first portion of the gas is used as a fuel for preheaters 24 and 26. The remaining top gas is mixed with natural gas in a ratio of 4:1 and recycled to the preheater 24.
- the top gas--natural gas mixture is heated to a temperature in the range of from about 650° C. to about 850° C., preferably to a temperature in the range of from about 680° to about 720° C.
- the heated top-natural gas mixture flows via a conduit 28 to a mixing chamber 30 at a flow rate of 1000 to 1100 NM 3 /ton DRI.
- Air preferably enriched with oxygen in a ratio of air to oxygen of 7:1 to 1:7 is heated by the preheater 26 to a temperature in the range of from about 650° C. to about 850° C., preferably to a temperature in the range of from about 680° to about 720° C.
- the heated air is then transported to the mixing chamber 30 via conduit 32 at a flow rate of 70 NM 3 /ton DRI and combined with the mixture of natural gas and top gas.
- the air--natural gas--top gas mixture Prior to introduction into the reaction zone 12, the air--natural gas--top gas mixture is partially combusted. This partial combustion raises the temperature to a temperature above 850° C. and preferably to a temperature of between 1000°-1100° C.
- This partially oxidized gas is delivered to the reaction zone 12 stoichometrically balanced to obtain a CH 4 /(CO 2 +H 2 O) ratio of about 0.63:1 to about 0.67:1 and an oxidation degree of 0.30 to 0.35.
- the gas mixture generally has a composition by volume of from about 35% to about 38% hydrogen, from about 15% to about 17% carbon monoxide, from about 18% to about 20% carbon dioxide, from about 15% to about 16% methane, from about 20% to about 22% nitrogen, from about 4% to about 7% water vapor, and from about 0.02% to about 0.3% C 2 H 6 .
- the entering gas mixture preferably has a degree of oxidation in the range of from about 0.27 to about 0.32 and a reducing power in the range of from about 2 to 3.
- the gas stream from the mixing chamber 30 is introduced into the reaction zone 12 at a flow rate of 1100 NM 3 /ton DRI.
- the gas is thus placed in intimate contact with hot descending DRI material and/or the partially metallized iron oxide bed in the reaction zone 12.
- the metallic solid iron acts as a catalyst providing from about 12 to 16 sq. met./gr. iron specific surface area for the catalytic reaction.
- the heat from its surfaces causes a highly endothermic reforming reaction to occur. This reaction is as follows:
- the pressure in the reactor is 1.2 atm.
- the resulting reformed gas has a composition by volume of from about 45 to about 48% hydrogen, from about 32% to about 34% carbon monoxide, from about 2% to about 4% carbon dioxide, from about 1% to about 3% methane, from about 14% to about 16% nitrogen and from about 1% to about 3% water vapor.
- the reformed gas is present in an amount from about 1100 NM 3 /ton to about 1450 NM 3 /ton with respect to the iron oxide material.
- the temperature of the gas in the reaction zone decreases to a reaction temperature in the range of from about 820° C. to about 850° C.
- this reformed reducing gas has a degree of oxidation in the range of about 0.05 to about 0.09 and a reducing power in the range of from about 11 to about 29.
- Table I below shows the composition of gases used in other direct reduction processes.
- the endothermic reaction (1) provides the amount of hydrogen and carbon monoxide required to carry out the following reduction reaction:
- reaction (2) also provides the carbon dioxide necessary to continuously maintain the reforming reaction.
- the ascending reducing gas produced in zone 12 has a composition containing methane, carbon monoxide, carbon dioxide, hydrogen, nitrogen and water vapor.
- a typical composition by volume is as follows: 5.4% CH 4 , 25.5% CO, 5.1% CO 2 , 46.5% H 2 , 1.5% H 2 O and 16.1% N 2 .
- This ascending gas contains sufficient reducing power and temperature to preheat and prereduce the iron oxide feed descending in zone 14 of the reactor 10.
- the process of the present invention takes advantage of the endothermic reaction taking place at the solid surface which hinders the effect of sinterization or sticking, thereby guaranting a smooth and continuous solid movement of the reduced material through the reactor. It should also be noted that no reformation of the reducing gas takes place outside of the reactor 10.
- the reforming and reduction reactions which takes place in the reaction zone 12 remove enough heat from the hot metallized product surface to hinder the effect of sintering, clustering or agglomeration of the metallized particles.
- the reactor 10 may comprise any suitable reactor known in the art.
- it may be a shaft-furnace moving--bed type of reactor.
Abstract
Description
CH.sub.4 +CO.sub.2 =2H.sub.2 +CO (1).
TABLE I __________________________________________________________________________ Reforming Gas Analysis % Process Fuel by:-- at:-- H.sub.2 CO CO.sub.2 H.sub.2 O N.sub.2 CH.sub.4 η-o ηH--C* __________________________________________________________________________ Wiberg Coal + top-gas 1100° C. 21.2 74.4 3.2 1.2 -- 0.04 0.29 oil steam Midrex Natural top-gas 900° C. 55* 35* 0.10* 1.6* Gas Purofer Natural top-gas up to 1 1 1 0.02 1.6* 1400° C. Armco Natural Steam 870° C. 68 20 2.0 8.5 0.1 1.1 0.105 3.5 Gas 1.4:1 Hyl Natural Steam 850° C. 75 14 8 3 0.03 3.3 Gas (2.1) __________________________________________________________________________ *Estimated from performance of reformer operating data and the fact that the principle reforming gas is CO.sub.2, top gas H.sub.2 O having been removed by scrubbing. ##STR1##
2FeO+H.sub.2 +CO=Fe+H.sub.2 O+CO.sub.2 (2).
Claims (12)
CH.sub.4 +CO.sub.2 =2H.sub.2 +CO.
2FeO+H.sub.2 +CO=Fe+H.sub.2 O+CO.sub.2.
Priority Applications (10)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US07/455,232 US5064467A (en) | 1987-11-02 | 1989-12-22 | Method and apparatus for the direct reduction of iron |
CA 2014308 CA2014308C (en) | 1989-12-22 | 1990-04-10 | Method and apparatus for the direct reduction of iron |
GB9008415A GB2239261B (en) | 1989-12-22 | 1990-04-12 | Process for the direct reduction of metal oxides |
US07/512,216 US5069716A (en) | 1989-12-22 | 1990-04-20 | Process for the production of liquid steel from iron containing metal oxides |
MX2041690A MX164566B (en) | 1989-12-22 | 1990-04-23 | METHOD AND APPARATUS FOR THE DIRECT REDUCTION OF IRON |
AR31678490A AR247592A1 (en) | 1989-12-22 | 1990-05-04 | Method and apparatus for the direct reduction of iron |
BR9003744A BR9003744A (en) | 1989-12-22 | 1990-07-31 | PROCESS OF DIRECT REDUCTION OF IRON CONTAINING METAL OXIDES |
DE19904025320 DE4025320C3 (en) | 1989-12-22 | 1990-08-10 | Process for the direct reduction of ferrous metal oxides |
US07/596,338 US5078788A (en) | 1989-12-22 | 1990-10-12 | Method for the direct reduction of iron |
JP29877890A JPH0788525B2 (en) | 1989-12-22 | 1990-11-02 | Direct reduction method of iron-containing metal oxide |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11591187A | 1987-11-25 | 1987-11-25 | |
US07/455,232 US5064467A (en) | 1987-11-02 | 1989-12-22 | Method and apparatus for the direct reduction of iron |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11591187A Continuation-In-Part | 1987-11-02 | 1987-11-25 |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US07/512,216 Continuation-In-Part US5069716A (en) | 1989-12-22 | 1990-04-20 | Process for the production of liquid steel from iron containing metal oxides |
US07/596,338 Continuation-In-Part US5078788A (en) | 1989-12-22 | 1990-10-12 | Method for the direct reduction of iron |
Publications (1)
Publication Number | Publication Date |
---|---|
US5064467A true US5064467A (en) | 1991-11-12 |
Family
ID=23807962
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US07/455,232 Expired - Fee Related US5064467A (en) | 1987-11-02 | 1989-12-22 | Method and apparatus for the direct reduction of iron |
Country Status (8)
Country | Link |
---|---|
US (1) | US5064467A (en) |
JP (1) | JPH0788525B2 (en) |
AR (1) | AR247592A1 (en) |
BR (1) | BR9003744A (en) |
CA (1) | CA2014308C (en) |
DE (1) | DE4025320C3 (en) |
GB (1) | GB2239261B (en) |
MX (1) | MX164566B (en) |
Cited By (16)
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US5387274A (en) * | 1993-11-15 | 1995-02-07 | C.V.G. Siderurgica Del Orinoco, C.A. | Process for the production of iron carbide |
US5912400A (en) * | 1997-12-02 | 1999-06-15 | Brifer International Ltd. | Method for reforming reducing gas in a fluidized bed process for reduction of ore |
US6045769A (en) * | 1997-12-08 | 2000-04-04 | Nanogram Corporation | Process for carbon production |
US6152984A (en) * | 1998-09-10 | 2000-11-28 | Praxair Technology, Inc. | Integrated direct reduction iron system |
US6270550B1 (en) | 1998-08-03 | 2001-08-07 | Hatch Associates Ltd. | Method for direct reduction of iron bearing pellets or lump iron ore |
WO2010028459A1 (en) * | 2008-09-15 | 2010-03-18 | Austpac Resources N.L. | Direct reduction |
US20100192729A1 (en) * | 2007-06-28 | 2010-08-05 | Siemens Vai Metals Technologies Gmbh & Co | Process and apparatus for producing sponge iron |
US20100264374A1 (en) * | 2009-04-20 | 2010-10-21 | Metius Gary E | Method and apparatus for sequestering carbon dioxide from a spent gas |
CN102851426A (en) * | 2012-10-09 | 2013-01-02 | 中冶赛迪工程技术股份有限公司 | Direct reduction process for producing spongy iron from CH4-rich coal gas |
WO2013013295A1 (en) * | 2011-07-26 | 2013-01-31 | Hatch Ltd. | Improved process for direct reduction of iron oxide |
US8771638B2 (en) | 2009-04-20 | 2014-07-08 | Midrex Technologies, Inc. | Method and apparatus for sequestering carbon dioxide from a spent gas |
CN104017923A (en) * | 2014-06-18 | 2014-09-03 | 汪春雷 | Ironmaking method and ironmaking furnace system |
CN105814215A (en) * | 2013-12-10 | 2016-07-27 | 株式会社Posco | Molten iron manufacturing method and molten iron manufacturing equipment |
US10065857B2 (en) | 2013-03-12 | 2018-09-04 | Midrex Technologies, Inc. | Systems and methods for generating carbon dioxide for use as a reforming oxidant in making syngas or reformed gas |
CN114774611A (en) * | 2022-03-31 | 2022-07-22 | 中晋冶金科技有限公司 | Hydrogen rich gas CO2Method for producing iron by oxidation conversion and hydrogen-based shaft furnace direct reduction |
CN114807486A (en) * | 2022-03-31 | 2022-07-29 | 中晋冶金科技有限公司 | CO (carbon monoxide) 2 Oxidative coupling of CH 4 Method and device for converting hydrogen production base shaft furnace reducing gas |
Families Citing this family (8)
Publication number | Priority date | Publication date | Assignee | Title |
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US5078788A (en) * | 1989-12-22 | 1992-01-07 | C.V.G. Siderurgica Del Orinoco, C.A. | Method for the direct reduction of iron |
CA2090906A1 (en) * | 1992-03-05 | 1993-09-06 | Corporacion Venezolana De Guayana (Cvg) | Method for improving quality of reforming gas used in the direct reduction of metal oxides |
DE19525270C2 (en) * | 1994-07-13 | 1999-08-26 | Int Steel Ind Engineering Co | Process for the production of pig iron from iron oxides |
AT409971B (en) * | 1998-11-19 | 2002-12-27 | Internat Briquettes Holding | Shaft furnace used for directly reducing metal oxides, especially iron oxides, comprises a reducing zone and a reforming zone divided by a refractory wall. |
EA201071418A1 (en) * | 2008-06-02 | 2011-06-30 | Эксонмобил Апстрим Рисерч Компани | GAS MONETIZATION OF REMOTE DEPOSITS USING MATERIALS WITH HIGH ENERGY DENSITY |
AT508522B1 (en) * | 2009-07-31 | 2011-04-15 | Siemens Vai Metals Tech Gmbh | REFORMERGAS-BASED REDUCTION PROCESS WITH REDUCED NOX EMISSION |
JP6135620B2 (en) * | 2014-08-22 | 2017-05-31 | Jfeスチール株式会社 | Hydrocarbon carbon dioxide reforming method |
DE102021112208A1 (en) | 2021-05-11 | 2022-11-17 | Thyssenkrupp Steel Europe Ag | Process for the direct reduction of iron ore |
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-
1989
- 1989-12-22 US US07/455,232 patent/US5064467A/en not_active Expired - Fee Related
-
1990
- 1990-04-10 CA CA 2014308 patent/CA2014308C/en not_active Expired - Fee Related
- 1990-04-12 GB GB9008415A patent/GB2239261B/en not_active Expired - Fee Related
- 1990-04-23 MX MX2041690A patent/MX164566B/en unknown
- 1990-05-04 AR AR31678490A patent/AR247592A1/en active
- 1990-07-31 BR BR9003744A patent/BR9003744A/en not_active IP Right Cessation
- 1990-08-10 DE DE19904025320 patent/DE4025320C3/en not_active Expired - Fee Related
- 1990-11-02 JP JP29877890A patent/JPH0788525B2/en not_active Expired - Lifetime
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US4528030A (en) * | 1983-05-16 | 1985-07-09 | Hylsa, S.A. | Method of reducing iron ore |
US4668284A (en) * | 1983-05-16 | 1987-05-26 | Hylsa, S.A. | Method of reducing iron ore |
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Also Published As
Publication number | Publication date |
---|---|
GB9008415D0 (en) | 1990-06-13 |
CA2014308A1 (en) | 1991-06-22 |
BR9003744A (en) | 1991-09-03 |
GB2239261A (en) | 1991-06-26 |
JPH0788525B2 (en) | 1995-09-27 |
DE4025320C3 (en) | 1999-07-15 |
JPH03274213A (en) | 1991-12-05 |
AR247592A1 (en) | 1995-01-31 |
MX164566B (en) | 1992-08-31 |
GB2239261B (en) | 1994-01-19 |
DE4025320A1 (en) | 1991-07-11 |
CA2014308C (en) | 1998-12-15 |
DE4025320C2 (en) | 1994-02-24 |
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